Harris Pye Deck Boiler

Harris Pye have been repairing, rebuilding and modifying boilers for the last 40 years. This experience has now be focused on our own range of boilers. Input was sought from the impressive collective experience and knowledge across the Group in both operation and maintenance of Marine and Offshore boilers.

Harris Pye provides complete turnkey boiler systems, encompassing every aspect of design, supply, and installation and commissioning. There are only a limited number of companies which can offer this technology and equipment to the market. Even less that can offer the turnkey possibility.

Harris Pye strive to make delivery options tailored to client requirements, delivered flat pack or part erected for assembly on site or fully assembled for direct lift onto installation. 

The boiler designs currently in the approval process with ABS are the result of the best we have to offer in this market. Our Proven Track Record includes: Boiler Repairs/ Flat Pack Erection, Ancillary System Maintenance & Supply, Automation & Combustion, Life Extension and Predictive Maintenance, Inspection & Design.

Boiler and system solutions are tailored to individual projects, allowing maximization of efficiencies due to fuel choice, and innovative maintenance options to significantly reduce down time and unplanned outages. 

Superheated Steam Deck Boiler units: Our harsh environment superheated steam deck boiler units generate an output capacity of 50T/hr – 120T/hr.  The units are roof fired and of membrane walled construction type and the range includes pressures from 40bar to 60bar. The model currently under ABS Class approval for marine application is a tri-fired (HFO/Gas/Light Oil), 60 t/hr steam output, 60bar pressure at 515°C.

Saturated Steam Deck Boiler units: Our harsh environment saturated steam deck boiler units generate an output of 15T/hr – 120T/hr, consisting of a roof fired, membrane walled construction type, currently under ABS Class approval for marine application (45T/hr, 16 bar, mono burner), operating at saturation temperature. 

Boiler Circulation Analysis: Harris Pye are capable of independently assessing the internal water circulation in any sub-critical boiler. Our computer based circulation modelling facility has been extensively field tested with both conventional primary element flow measurement and by radioactive tracer techniques carried out by the Australian Atomic Energy Commission.

Thermal Design: Harris Pye undertake thermal design of complex thermal systems (boilers, heat recovery steam generators (HRSGs), process heaters, etc.) and individual heat transfer components (furnaces, super heaters, evaporators, economisers, etc.) using our own in house proprietary design software. This software enables major changes in heating surface or geometry to be modelled quickly and accurately, ensuring the product is optimized and performs as designed.

Thermal Analysis: Harris Pye regularly undertake inspections and evaluations of boilers, heat recovery steam generators (HRSGs) and process heaters around the globe. Accurate independent measurement and analysis is used to assess plant operation and efficiency. This information is then used to suggest various improvements to equipment and operation procedures.

Mechanical Design: The mechanical design of the process equipment we build is performed iteratively alongside the thermal design procedure in order to provide fitness for purpose whilst optimizing key features; mechanical integrity, ease of manufacture & future maintenance, and reduction of superfluous materials. Careful material selection backs up design optimization and enables us to ensure longevity of individual components in the harsh environments we expect them to operate in.

Our design engineers work closely with all major classification bodies throughout the design period to ensure our proposals undergo stringent third party analysis and attain relevant code compliance in a timely fashion.

Fabrication Procedures: Harris Pye has extensive manufacturing facilities throughout the world each specialising in the manufacture of new, and refurbishment of old thermal process and heat transfer equipment. The latest addition to our manufacturing capabilities is a membrane wall panel welding and bending machine. These added facilities will provide Harris Pye with an edge over our competitors and the ability to produce furnace membrane walls quickly and of a consistent high quality. In addition to the recent acquisition of the membrane wall production machinery is our existing manufacturing capabilities; tube finning, plate rolling and cutting, tube bending, submerged arc and coded certified manual welding.

Throughout the procurement and fabrication processes rigorous quality control measures are implemented to ensure complete material traceability, dimensional accuracy, quality workmanship, and adherence to code & client specifications and work method statements are guaranteed.

Blast Analysis

Analysis of the conditions in which explosion may occur and estimation of the overpressure generated within the boiler, which are dependent on boiler parameters such as fuel, temperature, pressure or turbulence.

Design of measures to prevent damage to the boiler and to the operators. For example, the additional transient loads deriving from explosions in the furnace are accounted for in the design of buckstays and supporting systems. Similarly, appropriate venting devices can be used, designed according to the NFPA standards, in case of deflagrations in uptake sections.

  NFPA 68, Standard on explosion protection by deflagration venting, 2007 edition.

  NFPA 85, Boiler and combustion systems hazard code, 2011 edition.

Reduced Down Time

Operational maintenance will be required at various planned stages to ensure continued efficient and safe operation.  A reduction in the time required to carry out this maintenance is achieved by several innovative methods, including options for superheater element cassette removal (down to 3 – 4 days as opposed to a 28-day period if the traditional method were applied), efficient magnetite layer control and alternatives / reduction in refractory requirements.

 Asset Protection

In addition to the material selection and design, modern and proved alternatives to the traditional paint coatings have been incorporated into the design to protect against Corrosion Under Insulation (CUI) for up to and beyond 25 years’ service life.  Continuous online monitoring of the installation as part of the maintenance package also allows early detection of any plant or operational anomalies, allowing them to be rectified before they can result in adverse effects on the equipment. 

Improved Operation and Maintenance

Harris Pye believe in the continued support and training of the operators is essential in the safe and efficient operation of the installation.  On site training courses as well as installation specific simulators will be included in the scope of supply.  In addition to this, a remote operation and maintenance facility, ‘ROMS’, will also be offered to allow live operational support and system anomaly diagnosis to be carried out from one of our Global support centers.